Vehicle brake pedal with pedal resistance assembly and force/position sensor

ABSTRACT

A brake pedal assembly comprising a pedal and a pedal resistance force member operably coupled to the pedal. A damper pedal resistance force module defines an interior fluid-filled cavity. A shaft extends through the damper module and includes a piston mounted thereon and moveable through the fluid-filled cavity to generate a damper resistance force. A spring pedal resistance force module is adapted to generate a spring pedal resistance force. A pedal force sensing module is mounted to the pedal resistance force member. A pedal position sensor is mounted to the pedal resistance force member. A pedal force sensor is mounted to the pedal resistance force member.

CROSS REFERENCE TO RELATED APPLICATIONS

This patent application claims priority and benefit of U.S. ProvisionalPat. Application Serial No. 62/845,401 filed on May 9, 2019 and U.S.Provisional Pat. Application Serial No. 62/992,944 filed on Mar. 21,2020, the disclosure and contents of which are expressly incorporatedherein in their entireties by reference.

This patent application is also a divisional application which claimspriority and benefit of U.S. Application Serial No. 16/867,733 filed onMay 6, 2020 which is a continuation-in-part application of U.S.Application Serial No. 16/439,822 filed on Jun. 13, 2019, now U.S. Pat.No. 10,654,452 issued on May 19, 2020, which is a continuationapplication of U.S. Application Serial No. 15/876,772 filed on Jan. 22,2018, now U.S. Pat. No. 10,343,657 issued on Jul. 9, 2019, thedisclosures and contents of which are expressly incorporated herein intheir entireties by reference.

FIELD

This invention relates to a vehicle brake pedal with a pedal resistanceassembly and a force/position sensor.

BACKGROUND

Brake-by-wire vehicle brake pedals do not utilize a conventional vacuumor hydraulic system for braking.

There is a desire to replicate the feel of a conventional vacuum orhydraulic braking system in brake-by-wire vehicle brake pedals.

The present invention is directed to a brake-by-wire vehicle brake pedalincluding a pedal resistance assembly that replicates the resistancefeel of a conventional vacuum or hydraulic braking system.

The present invention is also directed to a pedal resistance assemblythat incorporates a pedal force/position sensor.

SUMMARY

The present invention is generally directed to a brake pedal assemblycomprising a pedal and a pedal resistance force member operably coupledto the pedal and including a damper pedal resistance force moduledefining an interior fluid-filled cavity, a shaft extending through thedamper module and including a piston mounted thereon and moveablethrough the fluid-filled cavity to generate a damper resistance force, aspring pedal resistance force module adapted to generate a spring pedalresistance force, a pedal force sensing module mounted to the pedalresistance force member, a pedal position sensor mounted to the pedalresistance force member; and a pedal force sensor mounted to the pedalresistance force member.

In one embodiment, the spring pedal resistance force module and thepedal force sensing modules are located at opposed ends of the pedalresistance force member.

In one embodiment, the spring pedal resistance force module and thepedal force sensing modules are located at the same end of the pedalresistance force member.

In one embodiment, the pedal resistance force member includes a moveablesleeve and a fixed sleeve, the moveable sleeve moving in response to themovement of the pedal, the shaft being operably coupled to the moveablesleeve and moveable in response to the movement of the moveable sleeve,the spring pedal resistance force module being coupled to the fixedsleeve and including first and second springs compressible in responseto movement and contact with the sleeve and the shaft respectively forgenerating the spring pedal resistance force.

In one embodiment, the pedal force sensing module is coupled to themoveable sleeve.

In one embodiment, the pedal resistance force member includes a moveablesleeve and a fixed sleeve, the moveable sleeve moving in response to themovement of the pedal, the shaft being operably coupled to the moveablesleeve and moveable in response to the movement of the moveable sleeve,the spring pedal resistance force module being coupled to the moveablesleeve and including a first spring compressible in response to movementof the moveable sleeve for generating the spring pedal resistance force.

In one embodiment, the pedal force sensing module is coupled to themoveable sleeve.

In one embodiment, the pedal force sensing module includes a deflectablestrain gauge plate with a deformable strain gauge element, the straingauge plate being deflectable and the strain gauge element beingdeformable in response to the application of a force against the straingauge plate.

In one embodiment, a bracket is coupled to the pedal and extending intothe pedal force sensing module and into contact with the deflectablestrain gauge, the bracket being adapted to exert a force against thedeflectable strain gauge in response to the movement of the pedal.

In one embodiment, a magnet is coupled to the stationary sleeve, thepedal position sensor comprising a Hall Effect sensor mounted to themoveable sleeve and adapted for sensing changes in the magnetic fieldgenerated by the magnet for determining the position of the pedal inresponse to the movement of the Hall Effect sensor relative to themagnet.

The present invention is also directed to a pedal resistance forcemember for a brake pedal and comprising a damper pedal resistance forcemodule defining an interior fluid-filled cavity, a shaft extendingthrough the damper module and including a piston mounted thereon andmoveable through the fluid-filled cavity to generate a damper resistanceforce, a spring pedal resistance force module adapted to generate aspring pedal resistance force, a pedal force sensing module mounted tothe pedal resistance force member, a pedal position sensor mounted tothe pedal resistance force member, and a pedal force sensor mounted tothe pedal resistance force member.

In one embodiment, the spring pedal resistance force module and thepedal force sensing modules are located at opposed ends of the pedalresistance force member.

In one embodiment, the spring pedal resistance force module and thepedal force sensing modules are located at the same end of the pedalresistance force member.

In one embodiment, the pedal resistance force member includes a moveablesleeve and a fixed sleeve, the moveable sleeve moving in response to themovement of the pedal, the shaft being operably coupled to the moveablesleeve and moveable in response to the movement of the moveable sleeve,the spring pedal resistance force module being coupled to the fixedsleeve and including first and second springs compressible in responseto movement and contact with the sleeve and the shaft respectively forgenerating the spring pedal resistance force.

In one embodiment, the pedal force sensing module is coupled to themoveable sleeve.

In one embodiment, the pedal resistance force member includes a moveablesleeve and a fixed sleeve, the moveable sleeve moving in response to themovement of the pedal, the shaft being operably coupled to the moveablesleeve and moveable in response to the movement of the moveable sleeve,the spring pedal resistance force module being coupled to the moveablesleeve and including a first spring compressible in response to movementof the moveable sleeve for generating the spring pedal resistance force.

In one embodiment, the pedal force sensing module is coupled to themoveable sleeve.

In one embodiment, the pedal force sensing module includes a deflectablestrain gauge plate with a deformable strain gauge element, the straingauge plate being deflectable and the strain gauge element beingdeformable in response to the application of a force against the straingauge plate.

In one embodiment, a bracket is coupled to a pedal and extends into thepedal force sensing module and into contact with the deflectable straingauge, the bracket being adapted to exert a force against thedeflectable strain gauge in response to the movement of the pedal.

In one embodiment, a magnet is coupled to the stationary sleeve, thepedal position sensor comprising a Hall Effect sensor mounted to themoveable sleeve and adapted for sensing changes in the magnetic fieldgenerated by the magnet for determining the position of the pedal inresponse to the movement of the Hall Effect sensor relative to themagnet.

Other advantages and features of the present invention will be morereadily apparent from the following detailed description of theembodiment of the invention, the accompanying drawings, and the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features can best be understood by the description ofthe accompanying FIGS as follows:

FIG. 1 is a simplified broken side elevational view of a vehicle brakepedal incorporating a first embodiment of a pedal resistance forceassembly or member in accordance with the present invention;

FIG. 2 is a perspective view of the pedal resistance force assemblyshown in FIG. 1 ;

FIG. 3 is a perspective view of one of the connectors with the positionand force sensor assembly and associated sensor integrated circuits andwake-up switch;

FIGS. 4 and 7 are vertical cross-sectional views of the pedal resistanceforce assembly shown in FIG. 2 in its fully engaged braking position;

FIG. 5 is a vertical cross-sectional view of the pedal resistance forceassembly shown in FIG. 2 in its rest or disengaged or non-brakingposition;

FIG. 6 is a vertical cross-sectional view of the pedal resistance forceassembly shown in FIG. 2 in a first partially engaged braking position;

FIG. 8 is a graph depicting the pedal resistance force generated by thepedal resistance assembly shown in FIGS. 1-7 as a function of pedaltravel;

FIG. 9 is a simplified broken side elevational view of a vehicle brakepedal incorporating another embodiment of a pedal resistance forceassembly or member in accordance with the present invention;

FIG. 10 is a perspective view of the pedal resistance force assemblyshown in FIG. 9 ;

FIG. 11 is a perspective view of one of the connectors incorporating theposition and force sensor integrated circuits of the pedal resistanceforce assembly of FIG. 9 ;

FIG. 12 is a perspective view of another of the connectors incorporatingthe wake-up switch of the position and force sensor integrated circuitsof the pedal resistance force assembly shown in FIG. 9 ;

FIG. 13A is a vertical cross-sectional view of the pedal resistanceforce assembly shown in FIG. 9 in its rest or disengaged or non-brakingposition;

FIG. 13B is a vertical cross-sectional view of the pedal resistanceforce assembly shown in FIG. 9 in its fully engaged braking position;

FIG. 14 is a vertical cross-sectional view of the pedal resistance forceassembly shown in FIG. 9 in a first partially engaged braking position;

FIG. 15 is a vertical cross-sectional view of the pedal force resistanceforce assembly shown in FIG. 9 in a second partially engaged brakingposition;

FIG. 16 is another vertical cross-sectional view of the pedal resistanceforce assembly shown in FIG. 9 in its fully engaged braking position;

FIG. 17 is an enlarged broken vertical cross-sectional view of the pedalresistance force assembly in the rest or disengaged or non-brakingposition as shown in FIG. 13 ;

FIG. 18 is an enlarged vertical cross-sectional view of the position ofthe check valves of the piston of the pedal resistance force assembly inthe FIG. 13A-16 positions of the pedal resistance force assembly;

FIG. 19 is an enlarged vertical cross-sectional view of the position ofthe check valves in the piston of the pedal resistance force assemblyduring the return of the pedal from its FIG. 16 position to its FIG. 13Aposition; and

FIG. 20 is a graph depicting the pedal resistance force generated by thepedal resistance assembly shown in FIGS. 9-16 as a function of pedaltravel.

DESCRIPTION OF THE EMBODIMENTS

FIGS. 1-7 depict a first embodiment of a vehicle brake pedal assembly 10incorporating a pedal resistance force assembly or module or member 100in accordance with the present invention.

The vehicle brake pedal assembly 10 includes a base/bracket 12, anelongate brake pedal 14 pivotally connected forclockwise/engaging/braking and counterclockwise/disengaging/non-brakingrotation and movement relative to the pedal base/bracket 12. The pedalresistance force assembly 100 is operably coupled to the pedal assembly10 in a relationship extending between the base/bracket 12 and the pedal14 and further in a relationship with a first end bracket 122 thereofoperatively coupled to the pedal 14 and a second opposed end bracket 123coupled to the pedal base/bracket 12.

The pedal resistance assembly 100 is generally in the form and shape ofan elongate hollow cylinder or housing or tube initially comprising aninterior liquid-filled cylinder or tubular damper or resistance forcemodule 110 adapted to provide a velocity-dependent force response andincluding a first central generally cylindrical elongate hollow interiorcylinder or tubular housing or sleeve 130 including an exteriorcircumferential wall 132 defining and forming an interior hollowelongate cylindrically or tubular shaped receptacle or cavity or chamber134 and further defining opposed ends 131 and 133.

A first sealing cap or cartridge 112 covers and seals a first end of thesleeve 130 of the damper module 110. A second opposed and spaced apartsealing cap or cartridge 114 covers and seals a second opposed end ofthe sleeve 130 of the damper module 110. The cavity or chamber 134contains a damper fluid (not shown) which, in one embodiment, can be apropylene glycol and water mixture.

The pedal resistance assembly 100 further comprises an elongate shaft140 extending through the interior of the chamber 134 of the sleeve 130of the damper module 110. The shaft 140 includes a first end 140 aextending through a central aperture defined in the cap 112 and a secondopposed end 140 b of the shaft 140 extending through a central aperturedefined in the opposed cap 114.

A piston 146 extends around a central portion or segment of the shaft140 and is located in the fluid cavity 134 between the two end sealingcaps 112 and 114. The piston 146 is fixed on the shaft 140 and ismoveable linearly in the interior of the fluid cavity 134 in response tothe back and forth linear movement of the shaft 140.

The piston 146 includes a dual rod structure adapted to maintain aconstant fluid volume during the stroke or movement thereof. Theinterior surface of the wall 132 of the sleeve 130 of the damper module110 includes variable geometry grooves 128 that allow the dampingfunction to vary with distance or movement of the piston linearly withinthe interior of the sleeve 130.

The pedal resistance assembly 100 still further comprises a secondhollow cylindrical or tubular sleeve or housing 153 surrounding thesleeve 130 of the damper module 110. The end 140 b of the shaft 140extends into the interior of the sleeve or housing 153. The sleeve 153includes opposed ends 153 a and 153 b. The damper module sleeve 130 islocated in the end 153 a of the sleeve 130.

A pair of elongate sensor magnets 154 a and 154 b are mounted on amagnet carrier 300 surrounding and fixed to the end 153 a of the sleeve153. The magnets 154 a and 154 b are located in a diametrically opposedrelationship on opposed sides of the magnet carrier 300 and thus ondiametrically opposed sides of the pedal resistance assembly 110.

A third hollow cylindrical or tubular sleeve or guide 155 surrounds thesecond sleeve or housing 153. The sleeve or guide 155 includes opposedends 155 a and 155 b. A collar 156 is defined at the one end 155 a ofthe sleeve or guide 155. The end 140 a of the shaft 140 extends througha central aperture defined in the collar 156.

A ring 159 surrounds and is fixed to the end 155 b of the sleeve orguide 155.

The pedal resistance assembly 100 still further comprises a spring pedalresistance force module 160 at one end thereof that is coupled to andsurrounds the end 153 b of the sleeve 153. The pedal resistance module160 includes the bracket 123 which includes an interior cylindricalcollar 162 surrounding the end 153 b of the sleeve 153 and a cylindricalpin or projection or finger 163 extending into the interior of the end153 b of the sleeve 153. The pedal resistance module 160 furtherincludes an interior cap 163 a that is moveable within the interior ofthe end 153 b of the sleeve 153. A ring 157 protruding inwardly from theinterior face of the wall of the sleeve 153 defines a stop that limitsthe movement of the cap 163 a in the interior of the sleeve 153.

A first compressible and expandable helical spring 164 extends aroundthe pin 163, is located in the interior of the end 153 a of the sleeve153 and includes opposed ends abutted against the interior collar 162and the interior of the bracket 123 respectively.

A second compressible and expandable helical spring 165 extends aroundthe exterior of the end 153 b of the sleeve 153 and includes opposedends abutted respectively against the collar 162 of the bracket 123 andthe ring 159 surrounding and fixed to the end 155 b of the sleeve orguide 155.

An exterior shroud 166 surrounds and covers the spring 165. A screw 167secures the shroud 166 to the bracket 123.

The pedal resistance assembly 100 still further comprises a pedal forcemodule 170 coupled to and partially surrounding the collar 156 at theone end 155 a of the sleeve or guide 155.

Thus, in the embodiment shown, the pedal resistance module 160 and thepedal force module 170 are positioned in a co-linear relationship alongthe longitudinal axis of the pedal resistance assembly 100 and locatedat opposed distal ends of the pedal resistance assembly 100 in arelationship with the damper or resistance force module 110 locatedbetween the pedal resistance module 160 and the pedal force module 170,all in a co-linear relationship relative to each other.

The pedal force module 170 includes an interior strain gauge housing 172that includes a center plate 173 and a circumferential collar 174surrounding the collar 156 of the sleeve or guide 155. An elongatespring pin 176 extends through the collars 174 and 156 and the end 140 aof the shaft 140. The housing 172 defines an interior chamber or cavityor receptacle for a pair of deformable Wheatstone bridge strain gaugediscs 180 and 182 separated by a spacer 184 and including strain gaugeelements (not shown) mounted thereon as known in the art.

The bracket 122 includes a pin 188 that extends through the strain gaugediscs 180 and 182 and through an aperture defined in the center plate173 of the housing 172. A preload lock nut 190 surrounds the end of thepin 188, is abutted against the plate 173, and secures the pin 188 andthus the bracket 122 to the housing 172. A shroud 192 surrounds thehousing 172.

The pedal resistance assembly 100 still further comprises a combinationposition and force sensor/sensing assembly or module 200 coupled to theexterior of the damper module 110 and, more specifically, to theexterior of the guide sleeve 155 of the damper module 110. The assembly200 comprises a pair of diametrically opposed connector assemblies 210and 220 mounted to the exterior of the guide sleeve 155. As shown inFIG. 3 , each of the connector assemblies 210 and 220 defines aninterior housing for a printed circuit board 222 including a positionsensor Hall Effect IC 224 and a pedal force sensor IC 226 mountedthereon. The pedal resistance assembly 110 includes a pair of connectorassemblies 210 and 220 and position sensor Hall Effect ICs and the pairof magnets 154 a and 154 b for redundancy reasons.

The connector assembly 210 also defines a housing for a position sensorwake-up switch 230 which, in one embodiment, may be a Reed type switch.The switch 230 is adapted to wake-up the respective position sensor HallEffect ICs 224 in response to the application of an initial brakingforce against the pedal 14.

A switch connector assembly 240 is also mounted to the exterior of thedamper module 110 and, more specifically, to exterior of the sleeve 155of the damper module 110.

Connector wires 250 a and 250 b extend between the respective straingauge elements 180 and 182 and the respective strain gauge sensor ICs226 mounted on the respective printed circuit boards 222 in the interiorof the respective connector assemblies 210 and 220. Another connectorwire 250 c extends between the wake-up switch 230 and the switchconnector assembly 240.

The combination of the pedal damper module 110 and the pedal resistancemodule 160 respectively are adapted to create and generate an increasingresistive force on the pedal 14 in response to the travel or movement orstroke of the pedal 14 during operation of a vehicle for either applyingthe brakes and increasing the resistance force or releasing the brakesand decreasing the resistance force as represented by the lines A and Bin the graph of FIG. 8 .

The combination of the damper module 110 and the spring 165 of thespring resistance module 160 create and generate an initial increasingresistance or feel force on the brake pedal 14 that is represented bythe point A in the graph of FIG. 8 . This initial increasing resistanceor feel force is generated in response to the depression of the pedal 14which, as shown in FIG. 6 , results in the forward movement of thebracket 122 which in turn results in the forward movement of the forcemodule 170 which in turn results in the forward sliding movementrelative to the sleeve 130 of the damper module 110 and the sleeve 153which in return results in the forward sliding movement of the shaft 140coupled to the sleeve 155 which in return results in the movement of thepiston 146 in the interior fluid filled cavity 134 of the damper module110 which in return generates the initial increasing dampening resistiveforce against the pedal 14.

An additional resistive force is generated against the pedal 14 as aresult of the compression of the spring 165 in response to the forwardsliding movement of the sleeve 155 which results in the forward movementof the ring 159 mounted thereon which causes the application of acompressive force against the one end of the spring 165 abutted againstthe ring 159 which in turn results in the compression of the spring 165and the generation of a resistive force against the pedal 14.

The additional depression of the pedal 14 results in the additionalforward movement of the sleeve 155 and the shaft 140 which results inthe additional compression of the spring 165 and still further resultsin the abutting contact of the end 140 b of the shaft 140 with the cap163 a which in turn and as a result of the further forward movement ofthe sleeve 155 and the shaft 140 results in the forward movement of thecap 163 a which in turn results in the compression of the spring 164which results in the generation of a still further increased resistiveforce against the pedal 14 which is represented by the line B in thegraph of FIG. 8 .

Although not described or shown herein in detail, it is understood thatthe lines B and A also represent the decreased pedal resistance force onthe pedal 14 generated when the vehicle operator removes foot pressurefrom the pedal 14 to release the brakes of the vehicle.

Additionally, the forward movement of the sleeve 155 results in theforward movement of the connector assemblies 210 and 220 mounted thereonand thus the movement of the position sensor Hall Effect ICs 224 mountedon the respective printed circuit boards 222 thereof relative to therespective stationary magnets 154 a and 154 b on the magnet carrier 300which results in the sensing by the respective Hall Effect ICs 224 ofthe changes in the magnitude and/or direction of the magnetic fields ofthe respective magnets 154 a and 154 b which results in the generationof respective electrical signals which are transferred to a control unit(not shown) for measuring and determining the position of the sleeve 155and thus the position of the pedal 14.

The forward movement of the connector assembly 210 also results in themovement of the reed switch 230 which in turn results in the activationof the switch 230 which in turn results in the wake-up of the respectiveposition sensor ICs 224 upon initial depression of the pedal 14.

Moreover, the depression of the pedal 14 results in the forward movementof the bracket 122 which in turn results in the bracket 122 applying aforce against the respective strain gauge discs 180 and 182 which inreturn results in a deformation or deflection of the respective discs180 and 182 that is sensed by one or more strain gauge elements 180 aand 182 a located on one or both of the exterior surfaces of the discs180 and 182 which results in a change of voltage that is sensed by therespective strain gauge elements 180 a and 182 a and the generation ofappropriate electric signals which are transferred to the pedal forcesensor IC 224 on the respective printed circuit board assemblies 222 ofthe respective connector assemblies 210 and 220 which signals aretransferred to a control unit (not shown) for measuring and determiningthe force being applied to the pedal 14. The pedal resistance assembly100 includes a pair of force sensor assemblies for redundancy reasons.

FIGS. 9-19 depict a second embodiment of a vehicle brake pedal assembly1010 incorporating a pedal resistance force assembly or module or member1100 in accordance with the present invention.

The vehicle brake pedal assembly 1010 includes a base/bracket 1012, anelongate brake pedal 1014 pivotally connected forclockwise/engaging/braking and counterclockwise/disengaging/non-brakingrotation and movement relative to the pedal base/bracket 1012. The pedalresistance assembly 1100 is operably coupled to the pedal assembly 101 oin a relationship extending between the base/bracket 1012 and the pedal1014 and more specifically in a relationship with a first end bracket1122 thereof operatively coupled to the pedal 1014 and a second opposedend bracket 1123 coupled to the pedal base/bracket 1012.

The pedal resistance assembly 1100 which is generally in the form andshape of an elongate hollow cylinder or housing or tube initiallycomprising a fixed or stationary liquid and air filled damper pedalresistance force module 1110 adapted to provide a velocity-dependentforce response and including a first central generally cylindricalelongate hollow interior housing or sleeve or tube 1130 including aninterior circumferential wall 1132 defining and forming an interiorhollow elongate cylindrically shaped receptacle or cavity or chamber1134 and further defining opposed ends 1131 and 1133.

The housing or sleeve 1130, and more specifically, the circumferentialwall 1132 thereof, also includes a plurality, and more specifically inthe embodiment shown three, spaced apart through-holes or apertures 1132a, 1132 b, and 1133 c extending around the circumference of the wall1132 and are radially spaced along the length of the wall 1132.

The housing or sleeve 1130, and more specifically the circumferentialwall 1132 thereof, also includes and defines a circumferential exteriorrecessed area or groove 1132 d in communication with the respectiveholes or apertures 1132 a, 1132 b, and 1133 c.

A first sealing cap or cartridge 1112 covers and seals the first end1131 of the sleeve 1130 of the damper module 1110. A second opposed andspaced apart cap or cartridge 1114 covers and seals the second end 1133of the sleeve 1130 of the damper module 1110. The bracket 1123 isunitary with the cap 1114.

The cavity or chamber 1134 includes an interior moveable generallycylindrical sealing plug or gasket or floating tan piston 1120 thatseparates the interior of the cavity or chamber 1134 into a firstchamber section 1134 a on one side of the plug or gasket 1120 thatcontains a damper fluid which, in one embodiment, can be a propyleneglycol and water mixture and a second chamber section 1134 b on theother side of the plug or gasket or piston 1120 that contains compressedair.

The cap or cartridge 1114 incorporates a Schrader or the like airpressure valve 1116 adapted for connection to a source of compressedair. The valve 1116 is in communication with an aperture or conduit 1117defined in the interior of the cap or cartridge 1114 which, in turn, isin communication with the interior of the second chamber section 1134 band adapted for the supply of compressed air into the interior of thesecond chamber section 1134 b as discussed in more detail below.

The pedal resistance assembly 1100 further comprises an elongate shaft140 extending through the interior of the chamber 1134 of the damper orresistance force module 1110, and more specifically through the interiorof the chamber section 1134 a of the sleeve 1130 of the damper module1110. The shaft 1140 includes a first end 1140 a and an opposed secondend 1140 b.

A piston 1146 extends around the first end 1140 a of the shaft 1140 andis located in the fluid cavity section 1134 a of the interior chamber1134 between the sealing cap 1112 and the sealing gasket or plug 1120.The piston 1146 is fixed on the shaft 1140 and is moveable linearly inthe interior of the fluid cavity section 1134 a of the chamber 1134 inresponse to the back and forth linear movement of the shaft 140 asexplained in more detail below.

The piston 1146 includes a plurality of check valves 1147 incorporatedtherein and extending between opposed sides of the piston 1146 andadapted to allow the liquid in the first chamber section 1134 a to movebetween the opposed sides of the piston 1146 as also described in moredetail below.

The pedal resistance assembly 1100 and, more specifically the damperpedal resistance force module 1110 thereof, still further comprises asecond hollow cylindrical or tubular stationary or fixed sleeve orhousing 1153 surrounding and fixed to the exterior of thecircumferential wall 1132 of the sleeve 1130 of the damper module 1110.The sleeve or housing 1153 includes opposed ends 1153 a and 1153 b. Theend 1153 a of the sleeve 1153 extends and protrudes fore of the end 1131of the sleeve 1130. The end 1153 b of the sleeve 1153 surrounds the end1133 of the sleeve 1130. The cap 1114 surrounds and is fixed to the end1153 b of the sleeve 1153.

The end 1153 a of the sleeve 1153 surrounds the first sealing cap orcartridge 1112 which covers and seals the first end 1131 of the sleeve1130 of the damper module 1110.

The sleeve 1153 surrounds and is fixed to the sleeve 1130 in arelationship wherein the groove 1133 d defined in the sleeve 1130 andthe interior surface of the wall of the sleeve 1153 defines a fluid flowchamber as described in more detail below.

A pair of elongate and diametrically opposed sensor magnets 1154 a and1154 b are located in respective grooves defined in the exterior face ofthe wall of the sleeve 1153. A switch magnet 1154 c is located inanother groove defined in the exterior wall of the sleeve 1153. Theswitch magnet 1154 c is positioned on the sleeve 1153 between and spacedninety degrees from the sensor magnets 1154 a and 1154 b.

The pedal resistance assembly 1100 still further comprises a springpedal resistance force module 1160 defined by a moveable and slidablesleeve 1161 including a first end 1161 a surrounding the end 1153 a ofthe sleeve 1153 of the damper or resistance force module 1110. Thesleeve 1160 defines an opposed end or radial collar or base 1161 b. Thesleeve 1161 also defines an interior chamber or cavity 1162.

A compressible and expandable helical spring 1164 is located in theinterior chamber or cavity 1162. A first end of the spring 1164 isabutted against the end of the interior cap 1112. A second end of thespring 1164 is abutted against a face of the collar 1160 b of the sleeve1161. The spring 1164 is compressible in response to the depression ofthe pedal 1014 and the resultant movement of the sleeves 1161 and 1153relative to each other as described in more detail below.

The end 1140 b of the shaft 1140 extends and is fixed in the end orcollar 1160 b of the sleeve 1161.

The pedal resistance assembly 1100 still further comprises a pedal forcemodule 1170 coupled to and partially surrounding the end 1160 b of thesleeve 1161.

The pedal force module 1170 includes an exterior collar orcircumferential wall or jacket 1171 defining an interior hollow housingor cavity 1178 that houses a deformable Wheatstone bridge strain gaugedisc 1180 including strain gauge elements (not shown) mounted thereon asknown in the art.

The pedal force module 1170 further comprises an interior bracket 1174located in the cavity 1178 and coupled to and abutted against the collar1160 b of the sleeve 1161.

An elongate pin 1176 extends successively through the end 1140 b of theshaft 1140, the collar 1160 b of the sleeve 1160, and the bracket 1174of the pedal force module 1170.

The bracket 1122 is coupled to and extends into the interior of thecollar 1171 of the pedal force module 1170. The bracket 1122 includes anoutwardly projecting pin 1188 that extends from the bracket 1122 intothe interior of the collar 1171, through the strain gauge disc 1180, andinto the interior bracket 1174. A preload lock nut 1190 surrounds and iscoupled to the distal end of the pin 1188 and secures the pin 1188 tothe bracket 1174.

Thus, in the embodiment shown, the pedal resistance module 1160 and thepedal force module 1170 are positioned in a co-linear relationship alongthe longitudinal axis of the pedal resistance assembly 1100 and locatedat the same distal end of the pedal resistance assembly 1100 in anadjoining side-by side co-linear relationship with the pedal resistancemodule 1160 in an adjoining side-by-side co-linear relationship with thedamper module 1110 and, still more specifically, in a side-by-sideco-linear relationship with the pedal resistance module 1160 locatedbetween the pedal force module 1170 and the damper module 1110 of thepedal resistance assembly 1100.

The pedal resistance assembly 1100 still further comprises a combinationposition and force sensor assembly 1200 coupled to the exterior of thepedal resistance module 1160 and, more specifically, to the exterior ofthe sleeve 1161 of the pedal resistance module 1160 and morespecifically comprises a plurality, and more specifically three,connector assemblies 1210, 1220, and 1230 mounted to the exterior of thesleeve 1161.

Each of the connector assemblies 1210 and 1220 defines a housing for aprinted circuit board 1222 including a position sensor Hall Effect IC1224 and a pedal force sensor IC 1226 mounted thereon. The pedalresistance assembly 1110 includes a pair of connector assemblies 1210and 1220 and position sensor Hall Effect ICs and the pair of magnets1154 a and 1154 b for redundancy reasons.

The connector assembly 1230 defines a housing for a position sensorwake-up switch 1232 which, in one embodiment, may be a Reed type switch.The switch 1232 is adapted to wake-up the respective position sensorHall Effect ICs 1224 in response to the application of an initialbraking force against the pedal 1014.

Connector wires 1250 a and 1250 b extend between the strain gaugeelement 1180 and the respective strain gauge sensor ICs 1226 mounted onthe respective printed circuit boards 1222 in the interior of therespective connector assemblies 1210 and 1220. Another pair of connectorwires (not shown) extends between the wake-up switch 1232 in theconnector assembly 1230 and the Hall Effect ICs 1224 in the respectiveconnector assemblies 1210 and 1220.

The combination of the damper and resistance modules 1110 and 1160respectively are adapted to create and generate an increasing resistiveforce on the pedal 1014 in response to the travel or movement of thepedal 1014 during operation of a vehicle for either applying the brakesand increasing the resistance force or releasing the brakes anddecreasing the resistance force as represented in the graph of FIG. 20 .

Point 1 in the graph of FIG. 20 represents the zero force F1 against thebrake pedal 1014 in the Zero travel x1 position of the brake pedal 1014in the disengaged or non-braking position of the pedal 1014 as shown inFIG. 9 and disengaged or non-braking position of the pedal resistanceforce assembly or module or member 1100 as shown in FIG. 13A.

The combination of the damper module 1110 and the spring 1164 of thespring resistance module 1160 are adapted to create and generate aninitial resistance or feel force F2 on the brake pedal 1014 that isrepresented by the Point 2 in the graph of FIG. 20 in response to thedepression of the pedal 1014 and resultant movement of the pedalresistance force assembly or module or member 1100 from its FIG. 13A andPoint 1 position to its first partially engaged braking Point 2 TravelX2 brake pedal position as shown in FIG. 14 .

This initial resistance or feel force is generated in response to thedepression of the pedal 1014 which, as shown in FIG. 14 , results in theforward movement of the bracket 1122 which in turn results in theforward movement of the force module 1170 which in turn results in theforward sliding movement of the sleeve 1161 relative to the sleeves 1130and 1153 of the damper module 1110 which in turn results in the forwardsliding movement of the shaft 1140 coupled to the sleeve 1161 which inturn results in the movement of the piston 1146 in the interior fluidfilled cavity 1134 of the damper module 1110 which in turn generates theinitial dampening resistive force against the pedal 1014.

An initial spring resistive force is also generated against the pedal1014 as a result of the compression of the spring 1164 in response tothe forward sliding movement of the sleeve 1161.

The additional depression of the pedal 1014 and the resultant movementof the pedal resistance force assembly or module or member 1100 from itsFIG. 14 Point 2 position to its FIG. 15 Point 3 Force F3 against thebrake pedal 1014 and Travel X3 engaged brake pedal position results inan additional increase in the pedal resistance force against the pedal1014 as shown in FIG. 20 .

Specifically, and referring to FIGS. 14 and 15 , the additional forwardmovement of the sleeve 1161 results in an additional compression of thespring 1164 which results in the application of an additional springresistive force against the pedal 1014.

The additional forward movement of the sleeve 1160 also results in theadditional forward movement of the shaft 1140 which results in theadditional forward movement of the piston 1146 in the interior fluidfilled cavity 1134 of the damper module 1110 which in turn generates andcreates an additional dampening resistive force against the pedal 1014.

Also, and referring to FIG. 17 , it is understood that the movement ofthe piston 1146 between the FIG. 13A and FIG. 15 positions results inthe movement of the fluid from the portion of the chamber 1134 locatedfore of the piston 1146 through the respective holes 1132 a, b, c andthe chamber 1132 d and into the portion of the chamber cavity 1134located aft of the piston 1146 for the purpose of allowing equalizationof the fluid volume within the interior of the chamber 1134 in responseto movement of the piston 1146 in the chamber 1134.

The still further depression of the pedal 1014 and the resultantmovement of the pedal resistance force assembly or module or member 1100from its FIG. 15 Point 3 position to its FIG. 16 Point 4 Force F4against the brake pedal 1014 and Travel X4 brake pedal position resultsin a still further increase in the pedal resistance force against thepedal 1014 as shown in FIG. 20 .

Specifically, and referring to FIGS. 15 and 16 , the still furtherforward movement of the sleeve 1160 results in a still furtheradditional compression of the spring 1164 which results in theapplication of a still further additional spring resistive force againstthe pedal 1014.

The still further additional forward movement of the sleeve 1161 alsoresults in the still further additional forward movement of the shaft1140 which results in the additional forward movement of the piston 1146in the interior fluid filled cavity 1134 of the damper module 1110 whichin turn generates and creates a still further additional dampeningresistive force against the pedal 1014.

As shown in FIGS. 14-16 , the forward movement of the piston 1146 withinthe chamber 1134 results in the blocking of successive ones of the fluidholes 1132 b and 1132 c defined in the wall 1132 of the sleeve 1130which in turn results in a build-up in the pressure of the fluid in thechamber 1134 which in turn results in the forward movement of the secondpiston 1120 in the chamber 1134 which in turn results in an increase inthe pressure of the air located in the chamber section 1134 b of thechamber 1134 which in turn results in the further additional increase inthe dampening resistance force against the pedal 1014.

Although not described or shown herein in detail, it is understood thatthe Points 4, 3, 2, and 1 in FIG. 20 also represent the decreased pedalresistance force on the pedal 1014 generated when the vehicle operatorremoves foot pressure from the pedal 1014 to release the brakes of thevehicle.

In this regard, it is understood that the removal of foot pressure fromthe pedal 1014 results in the rearward movement of the piston 1146 inthe chamber 1134 from its FIG. 16 position back to its FIG. 13A positionwhich results in the movement of the piston check valves from their FIG.18 closed position to their FIG. 19 open position in which the fluidlocated in the aft portion of the chamber 1134 is allowed to flowthrough the check valves 1147 and back into the fore portion of thechamber 1134.

Additionally, and independently, it is understood that the forwardmovement of the sleeve 1160 results in the forward movement of theconnector assemblies 1210 and 1220 mounted thereon and thus the movementof the position sensor Hall Effect ICs 1224 mounted on the respectiveprinted circuit boards 1222 relative to the respective stationarymagnets 1154 a and 1154 b which results in the sensing by the respectiveHall Effect ICs 1224 of the changes in the magnitude and/or direction ofthe magnetic fields of the respective magnets 1154 a and 1154 b whichresults in the generation of respective electrical signals which aretransferred to a control unit (not shown) for measuring and determiningthe position of the sleeve 1155 and thus the position of the pedal 1014.

The forward movement of the connector assembly 1230 also results in themovement of the reed switch 1232 relative to the switch magnet 1154 cwhich in turn results in the activation of the switch 1232 which in turnresults in the wake-up of the respective position sensor ICs 1224 uponinitial depression of the pedal 1014.

Moreover, the depression of the pedal 1014 results in the forwardmovement of the bracket 1122 which in turn results in the application ofa force against the strain gauge disc 1180 which in turn results in adeformation or deflection of the disc 1180 that is sensed by one or morestrain gauge elements 1180 a located on one or both of the exteriorsurfaces of the disc 1180 which results in a change of voltage that issensed by the respective strain gauge elements 1180 a and the generationof appropriate electric signals which are transferred to the pedal forcesensor IC 1224 on the respective printed circuit board assemblies 1222of the respective connector assemblies 1210 and 1220 which signals aretransferred to a control unit (not shown) for measuring and determiningthe force being applied to the pedal 1014. The pedal resistance assembly1100 includes a pair of force sensor assemblies for redundancy reasons.

Numerous variations and modifications of the embodiments of the pedalresistance assembly and pedal force/position sensors of the presentinvention as described above may be effected without departing from thespirit and scope of the novel features of the invention. It is to beunderstood that no limitations with respect to the embodimentsillustrated herein are intended or should be inferred. It is, of course,intended to cover by the appended claims all such modifications as fallwithin the scope of the claims.

1. A brake pedal assembly comprising: a pedal; and a pedal resistanceforce member operably coupled to the pedal and including: a damper pedalresistance force module defining an interior fluid-filled cavity; ashaft extending through the damper module and including a piston mountedthereon and moveable through the fluid-filled cavity to generate adamper resistance force; a spring pedal resistance force module adaptedto generate a spring pedal resistance force; a pedal force sensingmodule mounted to the pedal resistance force member; a pedal positionsensor mounted to the pedal resistance force member; and a pedal forcesensor mounted to the pedal resistance force member, wherein the springpedal resistance force module and the pedal force sensing modules arelocated at opposed ends of the pedal resistance force member. 2.(canceled)
 3. (canceled)
 4. The brake pedal assembly of claim 1 whereinthe pedal resistance force member includes a moveable sleeve and a fixedsleeve, the moveable sleeve moving in response to the movement of thepedal, the shaft being operably coupled to the moveable sleeve andmoveable in response to the movement of the moveable sleeve, the springpedal resistance force module being coupled to the fixed sleeve andincluding first and second springs compressible in response to movementand contact with the sleeve and the shaft respectively for generatingthe spring pedal resistance force.
 5. The brake pedal assembly of claim4 wherein the pedal force sensing module is coupled to the moveablesleeve.
 6. (canceled)
 7. (canceled)
 8. The brake pedal assembly of claim1 wherein the pedal force sensing module includes a deflectable straingauge plate with a deformable strain gauge element, the strain gaugeplate being deflectable and the strain gauge element being deformable inresponse to the application of a force against the strain gauge plate.9. The brake pedal assembly of claim 1 further comprising a bracketcoupled to the pedal and extending into the pedal force sensing moduleand into contact with the deflectable strain gauge, the bracket beingadapted to exert a force against the deflectable strain gauge inresponse to the movement of the pedal.
 10. The brake pedal assembly ofclaim 1 wherein a magnet is coupled to the stationary sleeve, the pedalposition sensor comprising a Hall Effect sensor mounted to the moveablesleeve and adapted for sensing changes in the magnetic field generatedby the magnet for determining the position of the pedal in response tothe movement of the Hall Effect sensor relative to the magnet.
 11. Apedal resistance force member for a brake pedal and comprising: a damperpedal resistance force module defining an interior fluid-filled cavity;a shaft extending through the damper module and including a pistonmounted thereon and moveable through the fluid-filled cavity to generatea damper resistance force; a spring pedal resistance force moduleadapted to generate a spring pedal resistance force; a pedal forcesensing module mounted to the pedal resistance force member; a pedalposition sensor mounted to the pedal resistance force member; and apedal force sensor mounted to the pedal resistance force member, whereinthe spring pedal resistance force module and the pedal force sensingmodules are located at opposed ends of the pedal resistance forcemember.
 12. (canceled)
 13. (canceled)
 14. A pedal resistance forcemember for a brake pedal and comprising: a damper pedal resistance forcemodule defining an interior fluid-filled cavity; a shaft extendingthrough the damper module and including a piston mounted thereon andmoveable through the fluid-filled cavity to generate a damper resistanceforce; a spring pedal resistance force module adapted to generate aspring pedal resistance force; a pedal force sensing module mounted tothe pedal resistance force member; a pedal position sensor mounted tothe pedal resistance force member; and a pedal force sensor mounted tothe pedal resistance force member, the pedal resistance force memberincluding a moveable sleeve and a fixed sleeve, the moveable sleevemoving in response to the movement of the pedal, the shaft beingoperably coupled to the moveable sleeve and moveable in response to themovement of the moveable sleeve, the spring pedal resistance forcemodule being coupled to the fixed sleeve and including first and secondsprings compressible in response to movement and contact with the sleeveand the shaft respectively for generating the spring pedal resistanceforce.
 15. The pedal resistance force member of claim 14 wherein thepedal force sensing module is coupled to the moveable sleeve. 16.(canceled)
 17. (canceled)
 18. The pedal resistance force member of claim11 wherein the pedal force sensing module includes a deflectable straingauge plate with a deformable strain gauge element, the strain gaugeplate being deflectable and the strain gauge element being deformable inresponse to the application of a force against the strain gauge plate.19. The pedal resistance force member of claim 11 further comprising abracket coupled to a pedal and extending into the pedal force sensingmodule and into contact with the deflectable strain gauge, the bracketbeing adapted to exert a force against the deflectable strain gauge inresponse to the movement of the pedal.
 20. The pedal resistance forcemember of claim 11 wherein a magnet is coupled to the stationary sleeve,the pedal position sensor comprising a Hall Effect sensor mounted to themoveable sleeve and adapted for sensing changes in the magnetic fieldgenerated by the magnet for determining the position of the pedal inresponse to the movement of the Hall Effect sensor relative to themagnet.
 21. The pedal resistance force member of claim 14 wherein thepedal force sensing module includes a deflectable strain gauge platewith a deformable strain gauge element, the strain gauge plate beingdeflectable and the strain gauge element being deformable in response tothe application of a force against the strain gauge plate.
 22. The pedalresistance force member of claim 14 further comprising a bracket coupledto a pedal and extending into the pedal force sensing module and intocontact with the deflectable strain gauge, the bracket being adapted toexert a force against the deflectable strain gauge in response to themovement of the pedal.
 23. The pedal resistance force member of claim 14wherein a magnet is coupled to the stationary sleeve, the pedal positionsensor comprising a Hall Effect sensor mounted to the moveable sleeveand adapted for sensing changes in the magnetic field generated by themagnet for determining the position of the pedal in response to themovement of the Hall Effect sensor relative to the magnet.
 24. The brakepedal assembly of claim 4 wherein the pedal force sensing moduleincludes a deflectable strain gauge plate with a deformable strain gaugeelement, the strain gauge plate being deflectable and the strain gaugeelement being deformable in response to the application of a forceagainst the strain gauge plate.
 25. The brake pedal assembly of claim 4further comprising a bracket coupled to the pedal and extending into thepedal force sensing module and into contact with the deflectable straingauge, the bracket being adapted to exert a force against thedeflectable strain gauge in response to the movement of the pedal. 26.The brake pedal assembly of claim 4 wherein a magnet is coupled to thestationary sleeve, the pedal position sensor comprising a Hall Effectsensor mounted to the moveable sleeve and adapted for sensing changes inthe magnetic field generated by the magnet for determining the positionof the pedal in response to the movement of the Hall Effect sensorrelative to the magnet.